SDS SDS DOUBLE SUCTION SPLIT CASE CENTRIFUGAL PUMPS

INSTRUCTION for INSTALLATION, OPERATION & MAINTENANCE

Pump Type : ..................Serial No : ..................Capacity : ..................m³/hHead : ..................mMotor Power : ..................kWSpeed : ..................rpm

BK SDS 00 06-11 EN

Instructions for Installation, Operation and Maintenance

Standart Pompa ve Makina San. Tic. A.Ş.

All rights reserved. Can not be copied or reproduced for any purpose without permission.Subject in the manual can be changed without any prior notice.

i

Contents

CONTENTS iIDENTIFICATION OF SAFETY AND WARNING SYMBOLS iiiGENERAL INSTRUCTIONS iiiSAFETY INSTRUCTIONS iii

A- GENERAL 1A1- Pump Description 1A2- Applications 1A3- Pump Designation 1A4- Pump Nameplate 1A5- Technical Data 1

B- UNCRATING, TRANSPORT AND STORAGE 2B1- Uncrating 2

B2- Transport 2 B2.1- General recommendations 2 B2.2- Lifting 2B3- Storage 3

C- INSTALLATION ON SITE 3C1- Bare Shaft Pump 3C2- Preparation For Installation 3

C3- Installation Site 3 C3.1- Foundation 3

C3.2- Installation 3 C4- Coupling Alignment 4 C5- Connection The Piping 5 C5.1- General 5 C5.2- Suction piping 6 C5.3- Discharge piping 6 C5.4- Auxiliary pipe connections and accessories 6 C5.5- Minimum flow 7 C5.6- Electrical connections 7 C5.7- Final check 8

D- START UP / SHUT DOWN 8 D1- Preparation 8

D1.1- Lubrication control 8 D1.2- Check the shaft seal 8

D1.3- Venting and priming 8 D1.4- Checking the direction of rotation 9 D2- Start Up The Pump 9 D3- Shut Down The Pump 9

D4- Checks To Be Made While The Pump Is Running 9

ii

E- LUBRICATION 10

F- DISASSEMBLY, REPAIR AND REASSEMBLY 10F1- Disassembly 10

F2- Reassembly 11 F3- Shaft Seal 11 F3.1- Pump with soft packing gland 11 F3.2- Pump with mechanical seal 11

G- SPARE PARTS 12H- FAULTS, CAUSES AND REMEDIES 12I- TIGHTENING TORQUES 14J- EXPECTED NOISE VALUES 14K- PERMISSIBLE FORCES AND MOMENTS AT THE PUMP FLANGES 15L- SECTIONAL DRAWINGS 16N- COUPLING GUARD AND SAFETY GUARD 17

iii

ATTENTION

This manual is intended to be a reference guide for users of pumps providing information on

Pump installation and maintenance instructions,Pumps start-up, operation and shut - down procedures.

IDENTIFICATION OF SAFETY AND WARNING SYMBOLS Safety instructions in this manual which could cause danger to life if not observed.

The presence of a dangerous electric current.

Non – observance to this warning could damage the machine or affect its functions.

GENERAL INSTRUCTIONS

- This manual should be kept in a safe place and ALWAYS be available to the QUALIFIED operating and maintenance personnel responsible for the safe operation and maintenanceof the pumps.

- Qualified personnel should be experienced and knowledgeable of safety standards.- To avoid faulty operation and malfunctioning of pumps the instructions in this manual are to be CAREFULLYstudied and followed at all stages of the pump installation and operating life.- The user is responsible for ensuring that inspection and installation are carried out by authorized and qualifiedpersonnel who have studied this manual carefully.- The pump should be used ONLY in the operating conditions given on the order for which the pump andmaterials of the construction have been selected and tested.- If the pump is to be used for a different application please contact sales office or representative of themanufacturer. STANDART POMPA refuses to assume any responsibility if the pump used for different applicationswithout prior written permission.- If the pump is not to be installed and operated soon after arrival, it should be stored in a clean and dry placewith moderate changes in ambient temperature. Extreme low or high temperatures may severely damage thepump unless suitable precautions are taken. The user is responsible for the verification of the ambient conditionswhere the pump will be stored or installed.- STANDART POMPA does not guarantee repairs or alterations done by user or other unauthorized personnel.The use of original spare parts and accessories authorized by manufacturer will ensure safety.- This manual does not take into account any site safety regulation, which may apply.

SAFETY INSTRUCTIONS

Strictly obey to the following instructions to prevent personal injuries and/or equipment damages:

- Pump should be used only in the specified operating conditions.- Any weight, stress or strains on the piping system should not be transmitted to the pump.- Electrical connections on the motor or accessories must always be carried out by authorized personnel andin accordance to the local codes.- Any work on the pump should be only carried out when the unit has been brought to standstill.

- Always disconnect the power to the motor and make sure not be switched on accidentallybefore working on the pump or removing the pump from installation.

- Any work on the pump should be carried out by at least two persons.- When approaching the pump always be properly dressed and/or wear safety equipment suitable for the workto be done.- Do not work on the pump when it is hot.- Do not touch the pump or piping with temperatures higher than 80 ºC. User must take suitable precautionto warn the persons (e.g. using warning signs, barrier).- Always be careful when working on pumps that handling dangerous liquids (e.g. acids or hazardous fluids).- Do not work on the pump when the pump and piping connected to the pump are under pressure.- After completion of the work always fix the safety guards back in places previously removed.- Do not run the pump in the wrong direction of rotation.- Do not insert hands or fingers into the pump openings or holes.- Do not step on the pump and/or piping connected to the pump.

1

SDS PUMPSA- GENERALA1- Pump description

SDS series pumps are horizontal, single stage, axially split volute casing pumps with double suction radialimpellers.

A2- Applications

SDS series pumps are suitable for clean or slightly contaminated (max. 20 mg/dm³) liquids with low viscositiesand temperatures up to 80º C. The main application areas, among others, are

Water supply, water treatment and irrigation systems,Warm water heating, chilled and cooling water systems.Water systems for industrial uses,Industrial circulating systems,Fire fightingPower Plants

A3- Pump Designation SDS 100 - 250

Pump typeDischarge nozzle (DN in mm)Number of stages

Pompa ve Makina San. Tic. A.Ş.

R

TP :Y:Q : m³/hP : kW D : mmn : rpm

H : mNo :

İDOS 2. Cad. No: 9Y. Dudullu/ ÜmraniyeiSTANBUL /TÜRKİYE+90 216 466 89 00

1

2

4

6

8

3

5

7

9

1- Pump Type and Size2- Production Year3- Serial No4- Capacity5- Head6- Motor Power7- Impeller Diameter8- Speed9- Direction of Rotation

A4- Pump Namplate

A5- Technical Data

Speed : up to 3600 rpm

Discharge Nozzle : DN 32 up to 400 mm

Suction Flanges : ISO 7005-2 / PN 16

Discharge Flanges : ISO 7005-2 / PN 25

Operating Temperature : -20 °C up to 105 °C

Ambient Temperature (max) : 40 ºC

Casing Pressure (max) : 16 bar - 25 bar

Permissible liquids : See A2

Fig. 1a. Bare shaft pump Fig. 1b. Pump and motor on a common baseplate

2

B- UNCRATING, TRANSPORT AND STORAGE

B1- Uncrating

Upon receipt verify that the goods received are in exact compliance with that listed on the packing list.Check that no visible damage exists on the crate that could have occurred during transportation.Carefully remove the packaging material and check that pump and accessories (if any) are free from anymarkings, stretches and damages, which may have occurred during transportation.In the event of damage report this immediately to STANDART POMPA’s service department and to thetransport company.

B2- Transport

B2.1- General recommendations

Existing regulations for the prevention of accidents must be followed.Wearing of gloves, hard-toed boots and hard hats is obligatory for all transport works.Wooden cases, crates, pallets or boxes may be unloaded with fork-lift trucks or using hoisting

slings, depending on their size, weight and construction.

B2.2- Lifting

Prior to lifting and moving the pump or pump and motor on a common base plate find out the following:

Total weight and center of gravityMaximum outside dimensionsLifting points location

The load-bearing capacity must be proper to the weight of the pump or the pump set.The pump or pump set must always be raised and transported in horizontal position.It is absolutely forbidden to stand beneath or nearby a raised load.A load should never remain in a raised position for longer than necessary.Accelerating and braking during the lifting process must be performed such that there is no danger to persons.

When lifting the pump or complete pump set lift them as shown in Fig.1a and Fig.1b respectively to avoid anydistortion (epecially do not use the motor eyebolt for carrying the complete unit).

3

ATTENTION

ATTENTION

ATTENTION

B3- Storage

If the pump is not to be installed and operated soon after arrival, store the pump in a clean, dry and frost-free place with moderate changes in ambient temperature.If the pump has regreaseable bearings, pump extra grease on bearings to prevent moisture from enteringaround the shaft.To prevent the pump from moisture, dust, dirt and foreign materials suitable steps should be taken.The pump shaft should be revolved periodically (e.g. once a week) to prevent pitting of the bearing surfacesand the pump from seizing up.

C- INSTALLATION ON SITE Installation has to be carried out in accordance with EN 60204-1.

The pump should only be installed, levelled up and aligned by skilled personnel. Incorrect installation ordefective foundation could result in troubles. This would not be covered by the warranty.

C1- Bare Shaft Pump

If the pump has been supplied with bare shaft end it is required to prepare a proper base plate on which tomount the pump and motor assembly. The base plate must be properly designed and manufactured for enoughrigidity to prevent vibrations and distortions. If the pump has been supplied without electric motor and coupling it is necessary to select a proper motorand coupling before proceeding to the installation of the unit.

The following considerations must be taken into account for selection of motor:Maximum power absorbed by the pump over the total operating range,Pump operating speed,Available power (frequency, voltage, etc.)Motor type (TEFC, exproof, etc.)Motor mounting position (foot mounted, flange mounted, horizontal, vertical, etc.)

When selecting coupling nominal motor power and operating speed must be taken into account.

C2- Preparation For Installation

Before installing the pump

Clean the suction and discharge flanges thoroughly.Remove the protective coating from the pump shaft. If the pump has been in temporary storage remove all the grease from the bearings with grease lubricatedor remove the oil from the bearing house if the pump is oil-lubricated, then clean the bearings with a suitablecleaning fluid and relubricate (NOTE: This is not necessary for the pumps with life time grease lubricatedbearings).

C3- Installation Site

The pump must be installed in a frost and dust-free, well-ventilated and non-explosiveenvironment.The pump should be installed such that there is space for access, ventilation, maintenance and there issufficient space above the pump for it to be lifted.The suction pipe should be kept as short as possible.

C3.1- Foundation

The greatest care must be taken in preparing the foundation and mounting the pump set.Incorrect installation will result in premature wear of pump components and break down of the pump.The foundation should be heavy enough to reduce vibrations and rigid enough to avoid any twisting ormisalignment. Make sure the concrete foundation has set firm and solid before mounting the pumpset. Thesurface of the foundation should be truly horizontal and perfectly flat.

C3.2- Installation

Place the pumpset on the concrete and by adding or removing shims under the baseplate align the dischargeflange horizontally by using a sprit level on it as shown on Fig.2 Make sure it is completely horizontal.

ATTENTION

Fig. 3. Aligning a flexible coupling

Fig. 4a. Angle error in horizontal plane and to settle

Fig. 4b. Angle error in vertical plane and to settle

Fig. 4c. Parallel sliding error in horizontal plane and tosettle

Fig. 4d. Parallel sliding error in vertical plane and tosettle

Slightly tighten the anchor bolts. Check the coupling alignment as explained in section C4.Fill in the baseplate with concrete. Make no air left in it and thebaseplate is well integrated with concrete foundation. Wait until the concrete firmly set (minimum 3 days).Tighten the anchor bolts. CHECK THE COUPLING ALIGNMENTAGAIN

C4- Coupling Alignment

For a trouble free service life of the pumping unitthe most important factor is aligning the coupling properly. Themain reason for vibration, noisy operation, warming bearings andoverloading is an unaligned or misaligned coupling. Thereforethe coupling should be correctly aligned and be checked frequently.

A flexible coupling should never be expected to correctmisalignment. A FLEXIBLE COUPLING IS NOT A CURE FORMISALIGNMENT AT ALL AND IT DOES NOT COMPENSATEFOR EXCESSIVE MISALIGNMENT. A flexible coupling will onlycompensate for small amount of misalignment.

“Coupling Alignment” means to secure the motorand pump rotation axes on the same straight line. SKM seriespumps are dispatched from our factory after the coupling alignmentis precisely secured if supplied with driver and baseplate. A certainamount of deformation of the baseplate is possible during handlingand transit. For this reason, regardless of the excellent alignmentmade at factory, THE PUMP AND DRIVER HAVE TO BEREALIGNED DURING INSTALLATION.

A 100 mm long metal stripe with straight edge (steel ruler) anda precise calliper are needed to align the coupling (specialinstruments must be used for a very fine and precise alignment).

There may be two forms of errors for coupling alignment:

a) Angular error,b) Parallel sliding error,

To check the angular error, the gap between the coupling halvesmust be the same at all points horizontally and vertically.

To control parallel sliding error, straight edged steel ruler ispressed down on one half of the coupling in parallel to the axis.It is checked against the other half. Straight edge must touch tothe both half couplings completely same at all points in eachvertical and horizontal planes (Fig. 3).

Alignment errors can be either on vertical plane or horizontalplane. On vertical plane alignment is corrected by inserting shimsunder the pump or motor foot, and on horizontal plane alignment is corrected by sliding the pump and/or motorhorizontally sideways by using the gaps at mounting holes. Fig. 4a, 4b, 4c, 4d show alignment of couplingstep by step.

Following any alternation, each alignment should be rechecked because any movement dueto an adjustment in one direction may cause misalignment in another.

Fig. 2. Foundation, baseplate and fitting the shims

ATTENTION

ATTENTION

a

4

5

C5- Connecting The Piping

C5.1- General

Never use the pump as an anchorage point or as a carrier for the piping.

The pipes should be supported very near the pump (Fig. 5). It must be checked that any weight, stress orstrains on the piping system should not be transmitted to the pump. Therefore after completing the pipinginstallation, the bolt and connection on the suction and discharge nozzles must be loosened to ensure thatthere is not any stress on the piping system to the pump.

The nominal sizes of the pump suction and discharge nozzles are no guide to the corrects sizes ofthe suction and discharge piping. The nominal bores of the pipes should be same as or greater than thoseof the pump nozzles. Never use pipes or accessories which have smaller bore than the pump nozzles.Particularly foot valves, strainers, filters and non return valves must be preferred with larger free transitionareas. In general the flow velocities should not exceed 2 m/s in the suction piping and 3 m/s in the dischargepiping. Higher flow velocities will result in higher pressure drops, which could cause cavitation conditions inthe suction piping and excessive friction losses in the discharge piping.

Pipe joints should be by means of flanges with flange gaskets of proper size and material. Flange gasketmust be centered between the flange bolts in a such way that there is no interference with the flow of the liquid.

Thermal expansions of the pipework and excessive vibrations should be accommodated by suitable meansso as not to impose any extra load on the pump.

Prevent impurities such as welding beads, scale, sand and tow might be left in pipes while production ofthe piping system harms the pump. Seal the pump nozzles by means of blind gasket to stop impurities get inthe pump. After assembling the system all the piping parts must be disassembled, thoroughly cleaned, paintedand reassembled again. If a strainer is used on the suction side of the pump, it must be cleaned after severaldays of operation.

ATTENTION

C5.2- Suction piping (Fig. 5, 6)

The suction piping must be absolutely leak-tight and not present any features likely to promote the formationof air pockets. Suction piping therefore should have a slight downward slope towards the pump in the caseof suction head installation (e.g. flooded suction) and slight upward slope towards the pump in the case ofsuction lift installation.

In order to keep the pipe friction losses as low as possible it is essential to avoid any sharp bends and abruptchanges of direction or cross-section and the suction pipe should be kept as short as possible. If it is necessaryto change the cross-section of a piping laid almost horizontal, an eccentric reducer, with top horizontal, shouldbe used.

A positive suction head piping should incorporate an isolating valve with the valve stem in the horizontalposition. This valve should always remain fully open while the pump is running and must not be used to regulatethe flow.

Fig. 5a. Suction Lift Fig. 5b. Suction Head

Piping Support

Piping Support

İsolating Valve

Long Radius Elbow

Long RadiusElbow

6

İsolation Valve

Vent Valve

Fig. 7.

Fig. 6a. Suction Lift Fig. 6b. Suction Head

Strainer

Foot Valve

EccentricReducer

Non Return Valve

Flow Control Valve

Flow Control Valve

Non Return Valve

İsolation Valve

EccentricReducer

C5.3- Discharge piping (Fig. 6)

A control valve should be installed in the discharge pipe, as close to the pump as possible, to regulate therequired flow and head.

If the total head of the pump exceeds 10 meters or if discharge line is of appreciable length a non returnvalve should be installed between the pump and isolating valve on the discharge line to protect the pumpagainst water hammer and reverse flow on shut down.

C5.4- Auxiliary pipe connections and accessories

Depending on the application auxiliary pipe connections (for cooling, sealingand flushing of seal, drainage etc. necessary for the pumping system) and/oraccessories to check the operating conditions (pressure gages, temperaturegages etc.) may be made up and laid.

Pressure and vacuum gauges must be properly anchored and connectedat the measuring points located on the pump flanges by means of or on thepipes close to the flanges approximately 8 mm diameter tubing with pig tailconfiguration to lessen pressure fluctuation. For safety purposes isolating andvent valves should be fitted before the gages (Fig. 7).

Every pump is fitted with connections on the pump casing to drain the pumpand on the bearing bracket to evacuate the seal leakage from the stuffing box(Fig. 8). If required the pump drain and seal leakage can be piped to a suitablereservoir. The pump draining piping must be fitted with an isolating valve andboth must be suitable for the maximum operating pressure of the pump.

Cooling, sealing and flushing of seal piping must be connected only to thedesignated connections located on the pump (See Fig. 8 to 12).

7

Fig. 8

Type of switch

Motor PowerPN 4 kW

Motor PowerPN > 4 kW

power supply3 ~ 400 V

power supply3 ~ 400 V

direct Y – connection (9b) – connection(9a)

Y / - start Impossible Remove connectingbridges (9c)

Table 1

d1 d2

d6

d7

d3d5

d4

d8

d4

C5.5- Minimum flow

If there is a possibility of the pump having to operate at zero flow (against a closed discharge valve) or nearthe closed valve with almost no flow, then a minimum flow valve (or a by-pass check valve) must be installedon the discharge nozzle or on the discharge piping right after the pump but before the flow regulating valve.In cases where there is no such a valve operating the pump against close valve for a long time causesconsiderable damage on the pump since almost all the motor power is transformed into thermal energy whichis absorbed by the pumped liquid.

C5.6- Electrical connections

The electrical motors have to be built in accordance with EN 60034-1.Enclosures of electrical motors and control systems on the pump unit shall as a minimumgive protection in accordance with EN 60529 IP22. But in determining the degree of protection ofenclosures of electrical motors and control systems on the pump unit the operating and environmentalconditions must be taken into consideration.Electrical connection should be done by a qualified electrician. Current national regulation and motormanufacturer’s instructions must be observed.Take all safety precautions listed in “Safety instructions”. Disconnect all power supplies prior to doing anywork.The supply cable must be laid in such a way that it never touches the pipework, pump and motor casing.Check voltage, phase and frequency on motor nameplate with the mains. The electric motor must be protected against overloading by means of circuit breakers and/or fuses. Circuitbreakers and fuses must be selected in accordance with full load amperage of the motor appearing on themotor rating plate.It is recommended to use PTC (passive thermal control) on motor, but this is optional depending on customerrequirement. In case of using PTC, these should be connected via corresponding terminals in the terminal boxand the PTC should be connected to the thermal trip mechanism.Prior to connecting the electrical wiring rotate the pump shaft by hand to make sure rotor rotates easily.Connect the electrical wiring in accordance with local electrical codes and make sure to ground the motor.The connection diagram can be found in the terminal box of the motor or in the instruction manual.The mains connection on the tagboard depends on the nominal power of the motor, the power supply andthe type of connection. The necessary connection of the bridges in the terminal box is shown in the following(Table 1. and Fig. 9a, 9b, 9c).

d1: Pressure gauge (suction).

d2: Pressure gauge (discharge).

d3: Filling or venting.

d4: Drain.

d5: Stuffing box flushing pipe.

d6: Air vent screw.

d7: Grease nipple.

d8: Seal leakage drain

8

Motor Power Y - set time

30 kW > 30 kW

< 3 sec> 5 sec

Table 2

W2 U2 V2

U1 V1 W1

L1 L2 L3

W1

V2

L1

V1

U2

U1

L2

W2

L3

W1

V2

L1

V1

U2

U1

L2

W2

L3

Fig. 9a. - connection Fig. 9b. Y – connection Fig. 9c. Y / - start

ATTENTION

ATTENTION

In the case of three-phase induction motors with Y – – connection it must be ensured thatthe change-over points between star and delta follow on from one another very quickly. Longer change-overtimes may result in pump damage (Table 2).

C5.7- Final check

After completion all the above process check the coupling alignment once more as described in C4. Correctif there is a fault. Rotate the pump rotor several times by hand. Make sure rotor rotates easily. Fix the safetyguards in places then run the unit until it warms up and normal operating conditions are reached. Now shut itdown and make final alignment by shimming driver only. Final alignment should be made at operatingtemperature.

Fix the safety guards back in places. Do not operate the pump before doing so. This is a necessity for security and job safety.

D- START UP / SHUT DOWND1- Preparation

D1.1- Lubrication control

Grease lubricated bearings are factory packed with grease enough for one year operation before dispatch.Before initial start up the pump it should be ascertained that no dirt has penetrated inside the bearing duringtransport or installation on site. Otherwise, the bearings should be cleaned out and repacked with fresh greasebefore start up.If the pump is stored for a long time before installation (more than 6 months) pump extra grease on bearings.See E for lubricating.

D1.2- Check the shaft seal (see F3)

D1.3- Venting and priming

Make sure that the pump and suction pipes are completely filled up with water. There is no problem for thepumps which have positive suction head. If there is a valve on suction line, it must be opened and air tapsare loosened to enable the water replaces air in the pump, until it is completely full with water.If there is a foot valve for the pump, which has suction lift, pump is filled up with water through the filling tapat the highest point of the pump and the air is emptied out.If the system has a vacuum pump, water is brought up in the rising pipe and filled up the pump through thisvacuum pump. When water is risen up to the highest point then the pump is started up.

Make sure the pump never runs dry.

9

D1.4- Checking the direction of rotation

SDS type pumps rotate in clockwise when it is looked from coupling to the pump. This direction is alreadyindicated on the pump nameplate by an arrow. Check this by switching the pump on, then off again immediately.Fit the coupling guard back in place if you took it out.

D2- Start Up The Pump

Check if the shut off valve in the suction line is open and the shut off valve in discharge line is closed.Switch on the circuit breaker and run the motor.Wait until the motor reaches the full speed (on star-delta running motors wait until it switches on delta).Open the discharge valve slowly while watching the ampermeter on the control panel (if the discharge lineis empty do not turn on the valve fully open on first start up. Turn it on slowly to maintain the value on theampermeter is under the rated current value of the motor).When the valve is if fully open, check the pressure on the manometer and see it is the same with the dutypoint pressure. If the pressure on the pressure gauge is lower than duty point pressure brings them to the dutypoint value by slightly closing the valve. If it is higher value, check your installation, particularly head again.

The pump should be shut down at once and the trouble should be corrected if the pump isrunning at its rated speed and found any of the following faults:

Pump doesn’t deliver any water,Pump doesn’t deliver enough water,Flow is going down,Discharge pressure is not enough,Driver overloaded,Vibration on pump,High noise level,Bearing overheating

D3- Shut Down The Pump

Slowly close the shut-off valve in the discharge line.You may shut down the pump without closing the shut-off valve if there is a device for water hammerprotection on the discharge line or the water hammer is not a considerable level.Switch off the driver. Ensure the pump set runs down smoothly and quietly to a standstill.Shut off external sealing liquid supply, if supplied, to relieve stuffing box pressure.If the set is to remain out of services for a long time close the shut-off valve in the suction pipe. Close offthe auxiliary connections. In the event of frost and/or prolonged standstill, drain the pump or otherwise protectagainst freezing.

D4- Checks to be Made While The Pump is Running

The pump must run smoothly, quietly and free from vibration at all times.The pump must never run dry.Never run the pump for along period against a closed discharge valve (at zero flow).The bearing temperature may exceed the ambient temperature by up to 50º C. But must never rise above80º C.The valves in the auxiliary lines must remain open while the pump is running.If the pump has soft packing type stuffing boxes, these should drip during operation. The gland nuts shouldonly be lightly tightened. In case of excessive leakage from the stuffing box tighten the gland nuts slowly andevenly until the leakage is reduced to the dripping state. Check the stuffing box for overheating by hand. Ifthe gland nuts can not be tightened any further remove the old packing rings and clean the packing chamberand insert the new packing rings. Make sure that each packing ring is cut of correct size. The joint in successivering should be offset to each other.If the pump has a mechanical seal, these will experience only minor leakage or no visible leakage duringoperation. It is maintenance free. If there is considerable leakage from the seal, that means the seal surfacesare worn-out and it needs to be replaced. The operation life of the mechanical seal highly depends on thepurity of the water.The flexible coupling elements should be regularly checked and replaced as soon as they are shown signsof wear.

ATTENTION

10

Occasionally check the motor current. Stop motor if the amperage is higher than usual; there may be jammingor friction in the pump. Make the necessary mechanical and electrical checks.Stand-By pumps should be run for a short time at least once a week to ensure they are in constant readinessfor operation. Check the integrity of auxiliary connections.

E- LUBRICATION

Bearing of SDS type pumps are either life-time grease lubricated or grease lubricated ball bearings.Life-time grease lubricated bearings are maintenance free.See the attached Table 3 for bearings type and size.

Periods of re-greasing

The grease should be changed after about 1500 to 2000 operating hours or if, owing to repeated shut-downs, the number of operating hours is not reached with in one year regrease the bearings in intervals ofapproximately 12 to 15 months. Using shorter intervals might result in overheating and consequently shortenbearing life.

The bearing temperature may exceed the ambient temperature by up to 50º C. But neverrise above 80º C.Do not reuse the bearings following disassembly for maintenance purposes.

F- DISASEMBLY, REPAIR AND REASSEMBLYBefore starting work on the pumpset, make sure it is disconnected from the mains and can not be switched on accidentally.

Follow the safety precaution measures outlined in “safety instructions”.

F1- Disassembly

Close all valves in the suction and discharge lines, and drain the pump by opening the drain plug (231) andthe air plug (230).Disconnect the stuffing boxes flushing pipes (500).Remove coupling guard and other safety guards (See section M for safety guard).Remove all casing main joint nuts and dowel pins.Separate the casing halves, lifting off the upper half casing (013).This reveals the pump internals (impeller,wear rings) for inspection.Unscrew the bolts which are connecting the bearing housings (030) to the bottom half casing (014).Lift the rotor out of the bottom half casing.Pull off the pump end coupling half from the shaft using a pull-off device and remove the coupling key (211).Remove bearing covers (034) and bearing end covers (035).Pull the bearing housing (030) off the bearings (200).Unscrew the shaft nuts and lock washers (391).Pull the bearings (200) off the shaft (060) and remove. Remove in sequence bearing covers (034), throwers (088), spacer sleeves (071), stuffing boxes (003),shaft protecting sleeves (070), wear rings (020), impeller (050) and impeller key (210).Clean all the parts, replace damaged or worn-out ones.

ATTENTION

Table 3

Shaft endDimension (ø)

Bearing Type

ABCDEFGH

Pump DimensionGroup*

354255657585100105

6308 C36310 C36312 C36314 C36317 C36319 C36322 C36324 C3

( * ) Grouped according to the shaft form.

11

F2- Reassembly

Reassembly proceeds in reverse sequence to dismantling as described in section F1. You may find theattached drawing useful. The following points should be noted more particularly:Never use old o-rings and make sure the new o-rings are the same size as the old ones.Before mounting the shaft protecting sleeves (070) inspect the condition of their rubbing faces. Use newsleeves if the old ones are badly worn, scored or rough.The joint faces of the casing halves are sealed with liquid sealing compound. The joint faces should bethoroughly cleaned before reassembly and coated over again with sealing compound. NEVER USE A PAPERGASKET BETWEEN THE TWO FACES.

F3- Shaft Seal

F3.1- Pump with soft packing gland

While starting to change soft packing thoroughly clean the stuffing box and shaft sleeve.Cut enough number of pieces at the suitable length diagonally from suitable size of soft packing. Roll it upover the shaft sleeve and see the ends are in full contact.Insert the first packing ring as the joint will place up, and press home using the gland cover.Place the second ring as joint will place down. Insert all the packing rings in the same way. If there is alantern ring put into place too.Place the gland and fully tighten, thus the packing rings will take the shape of stuffing box, then loosen it.Slightly tighten by turning the shaft and stop tightening when it slightly brakes the shaft.After starting operation, it is necessary that water drips from the packing. This dripping shouldn’t be lessthan 10 cm³/min and more than 20 cm³/min. Adjust dripping by uniformly tightening and slackering the glandnuts slightly.Check the temperature of soft packing after two hours operation after gland adjustment to avoid overheating.Packing temperature must not exceed 80ºC where pumping liquid temperature is the same as ambienttemperature.

F3.2- Pump with mechanical seal

When operating properly the mechanical seal has no visible leakage. Usually mechanical seals do not requiremaintenance until leakage is visible but its tightness is to be checked regularly.Follow the instructions of mechanical seal manufacturers for the pumps having mechanical seals and NEVERRUN IT DRY!Mechanical seal diameters are given in Table 4.

Table 4Mechanical SealDimension (ø)

ABCDEFGH

Pump DimensionGroup*

50607080100105125140

( * ) Grouped according to the shaft form.

12

PartNo

Part Name Number of pumps in the system

60

50

400

405

20

200

70

Shaft (Incl. keys)

Impeller

Wear Ring

Ball Bearings

Shaft sleeve

Soft packing (set)

Mechanical Seal (if used)

1

4

4

8

4

2

1

4

4

8

6

3

2

4

4

12

8

4

2

6

6

12

8

5

2

6

6

12

8

6-7

3

8

8

16

12

8-9

30%

10+

30%

50%

50%

50%

40%

90%

Table 5

420 O-Rings for casing 150%

1 1 1 2 2 3

2 2 4 4 6 8

4 6 8 8 9 12

H- FAULTS, CAUSES and REMEDIESIn this section you will find operating faults which may arise, and their causes (Table 6), and suggestedremedies (Table 7).

Before remedying operating faults, check all measuring instruments used for reliability andaccuracy.ATTENTION

FAULTS POSSIBLE CAUSES

1-5-7-10-11-13

2-3-8-14

9-12-17-18-19-27-28

19-20-21-22-24

15-16-19-23-25

4-6-26

Table 6

Pump doesn’t deliver any water after start-up

Flow is going down or no flow at all

Driver overloaded

Bearings overheating

Vibration on pump

Noise level is high

G- SPARE PARTS

STANDART POMPA guarantees to supply the spare parts for SDS type pumps for 10 years. You can provideany spare parts easily.Lets us know the following details on the name-plate, when you order spare parts.

Pump Type and Size : (SDS 125 - 315)Motor Power and Speed : (30 kW - 1450 rpm)Prod. Year and Serial Number : (2011 - 1445010)Capacity and Head : (200 m³/h - 30m)

If you prefer to have spare parts in your stock, we recommed you to have the following quantities for a twoyears operation depending on the number of same type of pumps (Table 5).

POSSIBLE CAUSESThere may be air existing in pump orsuction pipe

Ingress of air through shaft seal,suction pipe or suction port. Pumplifts liquid with air

Air pocket in the suction pipe.

There is air in liquid

Too much suction lift

Pump is working at cavitationconditions

Insufficient manometric head.

Increase at total manometric head.

Pump is operating at lowermanometric head.

Reverse rotation.

Speed is too low.

Speed is too high.

Impeller or check valve or strainer isclogged.Impeller or strainer is clogged partially.

Partially clogged impeller.

Worn out and defected impeller.

Mechanical frictions inside the pump.

Excess tightened soft packing.

Bad coupling alignment.

Bearing covers are too tight.The pumped flow is less than theminimum flow required.Existence of excess grease.

Oblique shaft.

Insufficient lubrication or lubricatingoil/grease dirty, contaminated.Unbalanced rotating parts.

Pump runs out of duty range.

The density or viscosity of the liquidpumped is higher than that originallyspecified.

Defects in motor.

Check the slope of the suction line make sure that there is no reasonfor formation of air pockets

Suction pipe is not submerged enough creating vortex. Check liquidlevel in suction tank or increase the depth of suction pipe or foot valvein the liquid.

If no obstruction at inlet check the friction losses of suction line, largerpiping may correct condition. If static lift is too high, the liquid level inthe suction tank must be raised or the pump lowered.

NPSH available is too low. Check liquid level in suction tank, checksuction line for excessive friction losses. Check isolating valve insuction line to make sure it is completely open. If necessary increasesuction head on pump by lowering the pump.

The actual total head is higher than that originally specified. Check thegeodetic total head and friction losses in the discharge line. Largerpiping may correct the condition. Check that valves are fully open.

Check that valves are fully open. Check that there is any obstruction indischarge pipe.The actual total head is lower than that originally specified. Machineimpeller outer diameter to size advised by supplier.Check motor rotation with directional arrow on pump casing ornameplate.

Check the supply voltage and frequency or motor may have open phase.

If possible decrease the pump rotational speed or turn down the impellerouter diameter to size advised by supplier.

Clean the impeller or check valve or strainer

Clean the impeller or strainer.

Clean the impeller.

Replace impeller.

Check pump rotor for any rotor obstruction or deflection.

Loosen the nuts of the packing gland.

Check the coupling rubber and realign the coupling.

Check and make necessary modification on the cover.

Increase the flow. If necessary use by-pass recirculating valve or line.

Remove excess grease.

Check the shaft and replace it if necessary.Check the amount of oil/grease. Clean the bearings and bearinghousing and relubricateCheck the balance of the rotating parts.

Check the values of operating point.

Use a more powerful motor.

Check any motor defects. The motor may not be ventilated properlydue to a poor location.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

REMEDIES

Table 7

Check for leaks in suction pipe joints and fittings. Check shaft seal ifnecessary increase the pressure of sealing liquid. Check the dept ofsuction pipe or foot valve in the liquid and if necessary increase thedepth of them.

Fill pump and suction pipe completely with liquid and repeat the primingprocedure.

13

14

I- TIGHTENING TORQUES

J- EXPECTED NOISE VALUES

(*) Without protective sound hood, measured at a distance of 1 m directly above the driven pump, in a free space above asound reflecting surface.

Tightening TorquesTightening Torque max (N.m)

Property ClassesThread Diameter8.8 10.93.05.9102549851352103004255807301100145019702530

4.48.715367212520031043061082010501550210027703560

M4M5M6M8M10M12M14M16M18M20M22M24M27M30M33M36

Power of MotorP

(kW)

Sound pressure level (dBA) *(Pump with motor)

1450 rpm 2900 rpm< 0.550.751.11.52.234

5.57.51115

18.522303745557590110132160

60606263646566676970727374757576777879808080

64666668697071737476777879818282848585868686

N

15

K- PERMISSIBLE FORCES AND MOMENTS AT THE PUMP FLANGES

* Forces in Newton [N], moments in Newton x Meter [N.m].** Volues are applicable for casing material “Grey Cast Iron (EN-JL-250 / GG25)”.

Higher values are permissible for steel construction pumps.

Factual

Fmax, allow

Mactual

Mmax, allow

Where total loads |F| and |M| are the arithmetic sumsfor each flange (inlet and outlet) without taking accounttheir algebraic sign.

The following condition must be satisfied;

Suction Flans Discharge Flans

65-25080-20080-25080-315

100-250100-315100-400125-315125-350125-450150-315150-450150-600200-315200-400200-500250-350250-450250-600300-315300-400300-500300-700350-350350-400350-500350-700400-800

Type DN Fx Fy Fz MxFb My Mz Mb DN Fx Fy Fz MxFb My Mz Mb100

125

150

200

200

250

250

300

350

400

400

500

600

1300

1600

2000

2700

2700

3300

3300

4000

4700

5300

5300

6600

8000

1200

1400

1800

2400

2400

3000

3000

3600

4200

4800

4800

6000

7200

1100

1300

1600

2200

2200

2700

2700

3200

3800

4300

4300

5400

6500

2100

2500

3100

4200

4200

5200

5200

6300

7300

8300

8300

10400

12500

530

630

750

980

980

1300

1300

1800

2300

2900

2900

4300

6100

380

450

530

690

690

950

950

1300

1700

2100

2100

3100

4300

440

570

620

800

800

1100

1100

1500

1900

2400

2400

3500

5000

780

920

1100

1400

1400

2000

2000

2700

3400

4300

4300

6400

9000

65

80

100

125

150

200

250

300

350

400

840

1000

1300

1600

2000

2700

3300

4000

4700

5300

740

900

1200

1400

1800

2400

3000

3600

4200

4800

680

820

1100

1300

1600

2200

2700

3200

3800

4300

1300

1600

2100

2500

3100

4200

5200

6300

7300

8300

450

480

530

630

750

980

1300

1800

2300

2900

330

350

380

450

530

690

950

1300

1700

2100

360

390

440

570

620

800

1100

1500

1900

2400

660

710

780

920

1100

1400

2000

2700

3400

4300

FH

FH

FV

16

L- SECTIONAL DRAWINGS

003 013421088

271

420 270 050 020 250 046

391

231 067

035

340

030

300

360

312

341

014

071

211

036

200

400

044

390

230

034

070210 500 042

392

060

* Optional

Stuffing BoxVolute Casing (top half)Volute Casing (bottom half)Wear RingBearing BracketBearing Cover (inboard)Bearing Cover (outboard)Bearing Cover (coupling)Stuffing Box GlandLantern RingStuffing Box Ring **Mechanical Seal CoverImpellerPump ShaftImpeller Dayama BurcuShaft Protecting SleeveSpacer SleeveThrowerBall Bearing

PART LIST003013014020030034035036042044046048050060067070071088200210

211212230231250260270300320321360390391392400405420421422500

Coupling KeySpacer KeyAir PlugDrain PlugAir Vent ScrewGrease NippleFlushing Pipe FittingStudHex.Head BoltHex.Head BoltHex. NutPinShaft NutLock WasherSoft PackingMechanical SealO-RingO-RingO-RingFlushing Pipe

048 422 405

Mechanical Seal Application

17

M- COUPLING GUARD AND SAFETY GUARD

Note: All guards are conforming to EN 294.

Safety guard Coupling guard

B

AB

A

EC DECLARATION OF CONFORMITY

Products: Pumps of type SDS with motor and baseplateManufacturer:Standart Pompa ve Makina San. Tic. A.Ş.Organize San. Bölgesi 2. Cad. No:934775 Esenkent / Ümraniye / İSTANBUL / TURKEYt: +90 216 466 89 00 f: +90 216 499 05 59www.standartpompa.com / info@standartpompa.com

The manufacturer herewith declares that the described products meet the essential requirements of MachineryDirective 2006/42/EC and Low Voltage Directive 2006/95/EC.

Harmonised standards applied are;

- EN 809- EN ISO 12100:2010- EN 60204-1

Şeref T. ÇELEBİGeneral Vice Manager

İstanbul, 12th January 2011

The product is marked with on its name plate.

MANUFACTURER DECLARATION OF CONFORMITY

Products: Pumps of type SDS (bareshaft)Manufacturer:Standart Pompa ve Makina San. Tic. A.Ş.Organize San. Bölgesi 2. Cad. No:934775 Esenkent / Ümraniye / İSTANBUL / TURKEYt: +90 216 466 89 00 f: +90 216 499 05 59www.standartpompa.com / info@standartpompa.com

The manufacturer herewith declares that the described products meet the essential requirements of MachineryDirective 2006/42/EC.

Before the pump is put into operation, the machinery unit in which the pump is functioning to be declared inconformity to relevant regulations.

Harmonised standards applied are;

- EN 809 - EN ISO 12100:2010

Şeref T. ÇELEBİGeneral Vice Manager

İstanbul, 12th January 2011

Tasarım ve boyut değişikliği hakkı saklıdır.Baskı hatalarından dolayı sorumluluk kabul edilemez.

Servis ve Yedek ParçaFabrika - Merkez

Yukarı Dudullu Organize San. Böl.2.Cad. No:9 34775İstanbul - TÜRKİYE

Pbx: +90 216 466 89 00Fax: +90 216 466 89 13

Yukarı Dudullu Organize San. Böl.2.Cad. No:9 34775İstanbul - TÜRKİYE

Pbx: +90 216 466 89 00Fax: +90 216 415 88 60